Modular Container

ABSTRACT

A modular container assembly includes a base and a lid configured to be removably coupled to the base to form a containment area. At least one corner brace is attached to the base adjacent a first corner to strengthen the base. An access channel is formed in the first corner of the base and extends beneath the corner brace to provide clearance behind the brace.

BACKGROUND

The present invention relates generally to containers, and particularly to modular container assemblies that are used to store tools and other objects.

Modular containers are used to store and transport many different objects. Some modular containers are stackable on top of one another for storage or shipment such that there is relatively little movement between the stacked containers. To facilitate stacking, the top surface of one container includes a feature that interlocks with a corresponding feature formed on a bottom surface of another container. Stacking the modular containers allows people handling the containers to optimize the available storage space within a building, as well as the space within a transport vehicle.

Most modular containers are constructed from a hardened polymer or similar material, and are crush-resistant to protect the objects within the container. However, such containers may still be vulnerable at their corners.

SUMMARY

The present invention provides a container assembly for storing and/or transporting goods such as tools. The container assembly includes a base, a lid, and a plurality of latching mechanisms positioned around the exterior surface of the base 40. The latches allow a user to secure the lid to the base. When coupled together, the lid and the base form an enclosed containment area in which a user can store and/or transport goods, such as tools and other objects.

The container also includes corner braces and a pair of wheel assemblies that are attached to the lower corners of the base. Each corner is further formed to include an elongated channel. The corner braces, the wheel assemblies, and the elongated channel strengthen the base and provide the container with stability.

The corner braces and the wheel assemblies are attached to the base such that a portion of the corner brace spans the elongated channel. This forms a clearance channel between each molded corner of the base and the corner braces. The clearance channels provide clearance behind the corner braces so that a tie down placed across the lid of the container can be connected to the corner braces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a container assembly according to one embodiment of the present invention.

FIG. 1B is a perspective view of a container assembly according to one embodiment of the present invention.

FIG. 2 illustrates a container assembly configured according to one embodiment of the present invention with the lid removed from the base.

FIG. 3A is a magnified view of a corner brace configured according to one embodiment of the present invention.

FIG. 3B is a magnified exploded view illustrating the components of the corner brace configured according to one embodiment of the present invention.

FIG. 4A is a magnified view of a wheel assembly configured according to one embodiment of the present invention.

FIG. 4B is a magnified exploded view illustrating the components of the wheel assembly configured according to one embodiment of the present invention.

FIG. 5 is a magnified view of a latch assembly for a container configured according to one embodiment of the present invention.

DETAILED DESCRIPTION

The present invention provides a container assembly for storing and/or transporting a variety of different objects, such as tools and other equipment. As seen in the figures and as described in the following specification, the container assembly comprises a two-piece, moldable, stackable case. Those skilled in the art will appreciate, however, that the present invention is not so limited, and that the container assembly need not be moldable or stackable, but rather, can be any type of container used for the storage and/or transportation of a variety of objects.

FIGS. 1A and 1B illustrate a container assembly 10 configured according to one embodiment of the present invention as seen from the top (FIG. 1A) and bottom (FIG. 1B) of the container 10, respectively. Container 10 comprises a two-piece molded, stackable container comprising a top section (or lid) 20 and a bottom section (or base) 40. A plurality of latch assemblies 120 are disposed around the perimeter of the container 10 to allow a user to secure the lid 20 to the base 40. When coupled, the lid 20 and the base 40 form a containment area 12 into which a user may place a variety of different objects for storage and/or transportation. Reinforcing corner braces 60 or 90 are disposed at each of the bottom corners of the base 40. As described in more detail later, the corner braces 60, 90 impart strength and stability to the container 10. Additionally, corner braces 90 may include wheel assemblies to facilitate the movement of the container 10 along an underlying support surface.

In some embodiments, one or more optional hinges 14 may be disposed on one side of the container 10 to allow the user to open and close the container 10 without having to lift the lid 20 from the base 40. In addition, a plurality of spring-loaded handles 16 may be disposed around the perimeter of the base 40 to assist the user in lifting and transporting the container 10. As is seen in FIGS. 1A-1B, the handle springs (not shown) will normally bias the handles 16 against the sidewall of the lid 20. Thus, after carrying the container by the handles 16, the springs would retract the handles 16 against the sidewall of the lid 20.

The lid 20 and base 40 may be manufactured together or separately, and may be constructed from any material needed or desired. However, in one embodiment, the lid 20 and base 40 are both manufactured as independent pieces. Particularly, each component is molded as a single piece from a material such as high-density polyethelyne (HDPE), for example. When cured, materials such as HDPE are sufficiently hard with which to provide a crush-resistant “shell” that helps to protect any cargo within the containment area 12 from being stolen or damaged.

The lid 20 comprises sidewalls 22 that extend downward from a periphery of a top surface 24. The top surface 24 includes a plurality of molded stacking features that allow one container 10 to be stacked with one or more other containers 10. In this embodiment, the stacking features comprise a plurality of raised members 26 and a plurality of raised ribs 28. The raised members 26 are generally octagonal in shape and are arranged on the top surface 24 in rows and columns; however, other arrangements are equally suitable. The raised ribs 28 extend between each raised member 26 and impart strength to the container 10. Together, the raised members 26 and the raised ribs 28 form a plurality of recesses 30 on the top surface 24 of lid 20. As seen in more detail below, the distribution of the recesses 30, as well as their size and shape, are formed to receive a plurality of complementary stacking features extending from a bottom surface of another container 10.

The base 40 also comprises a sidewall 42 that extends from a periphery of a bottom surface 44. The bottom surface 44 is formed to include a plurality of molded, raised stacking members 46 arranged in rows and columns. Both the size and shape the raised stacking members 46, as well as the arrangement of the raised stacking members 46 over the bottom surface 44, complements the recesses 30 formed on the top surface 24 of lid 20. Particularly, the raised stacking members 46 fit into the recesses 30 formed on lid 20 such that they interlock. This prevents containers 10 that are stacked upon one another from sliding or moving relative to one another. The geometry of the stacking features on both the lid 20 and base 40 allows for the stacking of containers 10, oriented in the same direction, or with the containers 10 rotated 90° with respect to one another.

Both the lid 20 and the base 40 may comprise a plurality of concavities or depressions 32, 48 integrally formed in the outer surfaces of their respective sidewalls 22, 42. When the lid 20 is coupled to the base 40, each depression 32 on the lid 20 generally aligns with a corresponding depression 48 formed in the sidewall 42 of lid 40. The depressions 48 in base 40 provide a recessed area for handles 16 and/or a first part of a latch 120, while the depressions 32 formed in the sidewall 22 of lid 20 provide a recessed area for a corresponding second part of the latch 120.

FIG. 2 illustrates the container assembly 10 with the lid 20 uncoupled and removed from base 40 to afford a view inside the assembly 10. As seen in FIG. 2, the peripheral edge of sidewall 22 is formed to include an integral groove 34. The groove 34 extends around the peripheral edge of the sidewall 22 and is sized to receive a gasket 36. The gasket 36 may be, for example, a rubber gasket formed in a continuous loop. When the lid 20 is coupled to the base 40, the gasket 36 contacts the peripheral edge of the sidewall 42 on base 40, and forms a substantially air-tight seal. This helps keep moisture and/or other contaminants from entering into the containment area 12 from the ambient environment when the container assembly 10 is closed. Further, depending upon the cargo, the gasket 36 also helps to prevent any materials (e.g., hazardous chemicals, etc.) that may be stored within the containment area 12 from escaping into and polluting the ambient environment.

As stated previously, tools and/or other objects may be stored and transported within the containment area 12. There is no restriction on the size or shape of the tools and/or objects, and therefore, the objects may be large and small. To help organize smaller objects within the containment area 12, the interior of base 40 may be configured to include one or more trays 50. Specifically, the interior surface of sidewall 42 may be molded to include a plurality of vertically-oriented, integrally-formed, elongated notches 52. Each notch 52 is configured to receive a tab (not shown) extending from the side of tray 50. The notches 52 are generally evenly spaced around the interior surface of the sidewall 42 so that a tray 50 may be positioned in multiple places within the containment area 12.

The elongated notches 52 may be formed in any manner known in the art; however, in this embodiment, the notches 52 are formed as trapezoids such that an open end of the notch 52 receiving a tab of tray 50 is slightly wider than an opposing, terminating end of the notch 52. The narrowing width of the notches 52 allows the notches 52 to “lock” the tabs into the notches 52 to help prevent movement of the tray 50.

FIGS. 3A-3B illustrate an exemplary reinforcing corner brace 60 according to one embodiment of the present invention. Each reinforcing corner brace 60 provides strength and stability to the container 10. As seen in FIGS. 3A-3B, a corner brace 60 comprises a unitary, rigid bracket 62 that fixedly attaches to the corner of base 40 using a plurality of mechanical fasteners 74. In this embodiment, mechanical fasteners 74 extend through beveled holes 72 formed in the bracket 62, and into a corresponding number of threaded receptacles 76 drilled into in the sidewall 42 and bottom surface 44 of base 40. The corner of the sidewall 42 may include a depression 56 that is sized and shaped to receive the corner brace 60 and prevent it from moving.

The bracket 62 may be constructed from any material known in the art; however, in one embodiment, the bracket 62 is formed as a unitary piece from a metal or metal alloy such as steel. The bracket 62 is then bent at predetermined angles thereby forming a first end section 64, a second end section 66, and an intermediate section 68 that generally conform to the shape of the corner on base 40. Alternatively, each of the first and second end sections 64, 66, and the intermediate section 68 are themselves separate pieces of steel and welded together at desired angles to form the complete bracket 62. As described in more detail below, an opening 78 is formed in the intermediate section 68 of the bracket 62, and provides a tie-down and/or lift point for the container 10.

The corners of the base 40 include an integrally-formed elongated channel 70. The channel 70 provides the base 40 with additional stability and strength. Channel 70 extends into the corner of base 40 and includes a first part 70 a and a second part 70 b. The first part 70 a has a generally smooth surface that is a substantially uniform depth from the exterior surface of the sidewall 42. The second part 70 b also has a substantially smooth surface, but is angled to extend towards the exterior surface of sidewall 42. The first and second parts 70 a, 70 b can have any dimensions needed or desired; however, in one embodiment, first part 70 a has a length l₁ that is about the same as the length l_(cb) of the bracket 62.

When attached to the base 40, the first and second end sections 64, 66 contact adjacent portions of the sidewall 22, and the bottom surface 44 of base 40. The intermediate section 68, however, is spaced away from the sidewall 42 such that it does not contact the exterior surface of base 40. More particularly, the intermediate section 68 spans the width of the elongated channel 70 in the corner of base 40 thereby forming a clearance channel 80 between the corner brace 60 and the surface of the first part 70 a. The access channel 80 is a space or clearance area behind the brace 60. With the clearance channel 80, a user can removably attach one end of a tie-down strap to an elongated opening 78 formed in the intermediate section 68. The user can then stretch the tie-down over the lid 20 of the container 10 (or another container 10 stacked on top), and attach the other end of the tie-down strap to a corresponding opening 78 formed in a corner brace 60 or 90 disposed on an opposite bottom corner of the container 10.

FIGS. 4A-4B illustrate another exemplary corner brace 90 configured according to one embodiment of the present invention. Each corner brace 90 provides strength and stability to the container 10, but also includes a wheel assembly to facilitate moving the container 10 over an underlying surface. As seen in FIGS. 4A-4B, the corner brace 90 comprises a unitary, rigid bracket 92, a wheel housing 96, and a wheel 104. The structure of the rigid bracket 92 is substantially similar to the structure of rigid bracket 62, and spans an elongated channel 70 formed in the corner of base 40 as previously described. Therefore, a clearance channel 80 is formed between the elongated channel 70 and the bracket 92. As above, the clearance channel 80 provides clearance behind the bracket 92 to allow a user to secure one end of a tie down (not shown) into an elongated opening 78 formed in the bracket 92.

As stated previously, this embodiment of the bracket 92 includes a wheel assembly 90. As such, the bracket 92 is slightly different than that of bracket 62. Particularly, bracket 92 comprises a tab 94 that extends downward from the bracket 92. When assembled, tab 94 abuts to, and aligns with, a corresponding tab 100 formed on the wheel housing 96. Both the tab 94 and the tab 100 include an opening 102 that, as described later in more detail, are aligned to support the wheel 104.

The wheel housing 96 is also a unitary rigid piece. It is constructed from a metal or metal alloy and has a plurality of terminal edges 98. In one embodiment, the wheel housing 96 is secured to the bracket 92 by welding one or more of the edges 98 to the exterior surface of the bracket 92. As seen in the figures, the wheel housing 96 houses a wheel 104 that permits a user to roll the container 10 over a smooth flat surface. An arched notch 112 is formed into the wheel housing 96 so that the wheel 104 is able to spin freely in the wheel housing 96.

The wheel 104 includes an axle 106, and bushings 108 a, 108 b disposed at each terminal end of the axle 106. The wheel 104 and/or the bushings 108 a, 108 b may be comprised of rubber or some similar material to dampen and/or absorb shock. In this case, the bushings 108 comprise first and second bushings 108 a, 108 b that support the axle 106 and the wheel 104. One of the bushings 108 a is supported within a depressed notch 110 integrally formed into the sidewall 42 of base 40. The other bushing 108 b is supported within the aligned openings 102 formed in the aligned tabs 94 and 100.

As stated above, a plurality of latch assemblies 120 may be disposed around the periphery of the base 40 to secure the lid 20 to the base 40. As those skilled in the art will readily appreciate, any latch known in the art will allow a user to secure the lid 20 to the base 40. For example, FIGS. 1A-1B illustrated some exemplary latches 120 as being conventional rotary draw latches. However, in at least one embodiment, the present invention provides an enhanced rotary draw latch 120 for use on container 10.

FIG. 5 is a perspective view illustrating one embodiment of the rotary draw latch 120 provided in one embodiment of the present invention. The rotary draw latch 120 comprises a first part 122 secured to sidewall 22 of lid 20, and a second part 124 secured to sidewall 42 of base 40. Rivets or other mechanical fasteners may be used to affix the first and second parts 122, 124 of rotary draw latch 120 to their respective sidewalls 22, 42.

According to one embodiment of the present invention, the rotary draw latch 120 may include an arm 130 secured to the second part 124 of rotary draw latch 120. The arm 130 is constructed of a unitary piece of metal or metal alloy, and is formed to include one or more bends and turns as needed or desired. In this embodiment, the arm 130 comprises a first section 132 that connects to the second part 124 of rotary draw latch 120, and a second section 136 that extends from the first section 132. A slot 136 is formed in the second section 134 of the rotary draw latch 120. The slot 136 is sized and placed on the second section 134 to receive a corresponding tab 140 that is attached to and extending outwardly from the sidewall 42 of base 40. The tab 140 includes an opening 142 through which a user can connect a padlock (not shown). Once locked, the arm 130 maintains the second part 124 of the rotary draw latch 120 in a static position against the sidewall 42 of base 40 such that a person cannot turn the latch. This prevents unauthorized users from turning and unlatching the rotary draw latch 120 to gain access to the containment area 12.

The present invention may, of course, be carried out in other ways than those specifically set forth herein without departing from essential characteristics of the invention. The present embodiments are to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. 

1. A modular container assembly comprising: a base; a lid configured to be removably coupled to the base to form a containment area; a corner brace attached to the base adjacent a first corner to strengthen the base; and a clearance channel formed in the first corner of the base and extending beneath the corner brace to provide clearance behind the brace.
 2. The modular container assembly of claim 1 wherein the clearance channel comprises an elongated recess formed in the base to extend at least partially along the first corner.
 3. The modular container assembly of claim 2 wherein the elongated recess is formed to include an angled surface.
 4. The modular container assembly of claim 1 wherein the corner brace comprises: first and second end sections configured to fixedly attach to adjacent portions of the sidewall of the base; and an intermediate section disposed between the first and second end sections and spanning the clearance channel.
 5. The modular container assembly of claim 4 wherein the first and second end sections are further attached to a bottom surface of the base.
 6. The modular container assembly of claim 4 further comprising an opening formed in the intermediate section of the brace and over the access cavity.
 7. The modular container assembly of claim 6 wherein the opening is sized to receive an end of a tie down.
 8. The modular container assembly of claim 6 wherein the opening provides a lifting point used to lift the container.
 9. The modular container assembly of claim 1 wherein the base includes an indentation formed in the first corner shaped to receive the corner brace.
 10. The modular container assembly of claim 1 further comprising a wheel assembly attached to the brace.
 11. The modular container assembly of claim 10 wherein the wheel assembly comprises: a bracket configured to attach to an exterior surface of the corner brace; and a wheel having an axle that rotatably connects the wheel to the base, the corner brace, and the bracket.
 12. The modular container assembly of claim 11 wherein the corner brace and the bracket include corresponding through-holes that receive a terminal end of the axle.
 13. The modular container assembly of claim 11 further comprising a pair of bushings sized to connect the terminal ends of the axle to the base and the bracket to absorb shock.
 14. The modular connector of claim 1 further comprising a latch to secure the lid to the base, the latch comprising an arm extending from an actuator on the latch to the container.
 15. The modular connector of claim 14 wherein the arm comprises slot formed at one end to receive a lock that prevents opening the latch.
 16. The modular connector of claim 1 wherein the corner brace comprises a first corner brace, and further comprising: a second corner brace attached to the base adjacent a second corner to strengthen the base; and a second clearance channel formed in the second corner of the base and extending beneath the second corner brace to provide clearance behind the second brace.
 17. The modular connector of claim 16 further comprising a wheel assembly fixedly attached to the second corner brace.
 18. The modular connector of claim 1 further comprising an opening formed in the corner brace over the clearance channel configured to receive a tie down.
 19. The modular connector of claim 1 further comprising a gasket to seal the lid and the base.
 20. A modular container assembly comprising: a base having a plurality of corners; a lid configured to be removably coupled to the base to form a containment area; a corner brace attached to each corner of the base to strengthen the base; a clearance channel formed in each corner of the base and extending beneath the corresponding corner brace to provide clearance behind the corresponding corner brace; and a pair wheels respectively attached to first and second corner braces to permit movement of the container over an underlying ground surface. 